HUSQVARNA TE 250I 2022 (01) PDF DOCUMENT

Briefly press the left or right buttons to cycle through the different display modes.

DST (Distance 1) Mode:

– Press one of the buttons until DST appears. This mode shows speed, time, and distance since the last reset. If the value of 39999.9 is exceeded, DST automatically resets to 0.0.

– To reset DST to 0.0, press the right button for 3-5 seconds.

– To preset a value for DST, press the left button for 3-5 seconds.

DST2 (Distance 2) Mode:

– Press one of the buttons until DST2 appears. This mode shows speed, time, and distance 2 since the last reset. If the value of 39999.9 is exceeded, DST2 automatically resets to 0.0.

– To reset DST2 to 0.0, press the right button for 3-5 seconds.

– To preset a value for DST2, press the left button for 3-5 seconds.

AVG, ART, ODO Mode:

– Press one of the buttons until AVG, ART, and ODO appear.

– AVG shows the average speed since the last reset.

– ART shows the operating hours.

– ODO shows the total distance covered.

– To reset AVG to 0.0, press the right button for 3-5 seconds.

– To view the remaining operating hours until the next service, press the left button for 3-5 seconds.

– Make sure that the pre-sale inspection work has been carried out by an authorized workshop.

– Before riding for the first time, read the entire Owner’s Manual carefully.

– Get to know the controls.

– Adjust the basic position of the clutch lever.

– Adjust the basic position of the hand brake lever (All TE standard models).

– Adjust the free travel of the handbrake lever (All TE special models).

– Adjust the basic position of the foot brake lever.

– Adjust the basic position of the shift lever.

– Get used to the handling characteristics of the motorcycle on a suitable surface before undertaking more challenging trips.

– Try also to ride as slowly as possible and in a standing position to get a better feel for the motorcycle.

– Do not make any off-road trips that exceed your ability and experience.

– Hold the handlebar firmly with both hands and keep your feet on the footrests when riding.

– If you carry luggage, make sure you secure it firmly as close as possible to the center of the vehicle and ensure even weight distribution between the front and rear wheels.

– The maximum permissible overall weight and the maximum permissible axle loads must not be exceeded.

– Check the spoke tension. The spoke tension must be checked after half an hour of operation.

– Run the engine in.

– During the running-in phase, do not exceed the specified engine performance.

– Avoid fully opening the throttle!

– Check the idle speed regularly.

The idle speed may change during the run-in time. If the idle speed changes, adjust the idle speed.

Lithium-ion batteries are far lighter than lead batteries, have a low self-discharge rate, and have more starting power at temperatures over 15 °C (60 °F). At low temperatures, however, the starting power of lithium-ion batteries drops to below that of lead batteries.

Multiple starting attempts may be needed. Press the start button for 5 seconds, and wait 30 seconds between attempts. The pauses are necessary so that the heat created can distribute through the lithium-ion battery and the 12-V battery is not damaged.

If the charged lithium-ion battery is unable to actuate the starter motor when temperatures are below 15 °C (60 °F), the battery is not faulty, but needs to be warmed up internally to increase its starting power (current output).

The starting power increases as the battery warms up.

Use of the vehicle under difficult conditions, such as on sand or on wet and muddy surfaces, can result in significantly increased wear of components, such as the drive train, brake system, or suspension components. For this reason, it may be necessary to inspect or replace parts before the next scheduled service.

– Clean the air filter and air filter box. Check the air filter approx. every 30 minutes.

– Check the electrical connector for humidity and corrosion and to ensure it is firmly seated.

» If humidity, corrosion, or damage is found: Clean and dry the connector, or change it if necessary.

Difficult operating conditions are:

– Rides on dry sand.

– Rides on wet sand.

– Rides on wet and muddy circuits.

– Rides at high temperatures or slow riding.

– Riding at low temperatures and in snow.

Before every trip, check the condition of the vehicle and ensure that it is safe to operate. The vehicle must be in perfect technical condition when it is being operated.

– Check the gear oil level.

– Check the electrical system.

– Check the front brake fluid level.

– Check the rear brake fluid level.

– Check the front brake linings.

– Check the brake linings of the rear brake.

– Check that the brake system is functioning properly.

– Check the coolant level.

– Check the chain for dirt.

– Check the chain, rear sprocket, engine sprocket, and chain guide.

– Check the chain tension.

– Check the tire condition.

– Check tire pressure.

– Check the spoke tension. (Incorrect spoke tension will strongly impair riding safety).

– Clean the dust boots of the fork legs.

– Bleed the fork legs.

– Check the air filter.

– Check the settings of all controls and ensure that they can be operated smoothly.

– Check all screws, nuts, and hose clamps regularly for tightness.

– Check the fuel level.

– Check 2-stroke oil level.

Warning: High revving speed with a cold engine negatively impacts the lifespan of the engine. Always run the engine warm at a low speed.

1. Take the motorcycle off the side stand and secure the side stand with the rubber strap.

2. Shift the transmission into neutral.

3. (All EU/AR/CN models) Turn the emergency OFF switch to the ON position (circle icon).

4. Condition: Ambient temperature < 10 °C (< 50 °F)

– Pull the cold start button out all the way and turn it by a ¼ turn. If the engine is warm, the cold start button must be deactivated.

5. Press the start button.

– Do not open the throttle.

– Press the start button for a maximum of 5 seconds. Wait for 30 seconds before a further attempt at starting.

– At temperatures below 15 °C (60 °F), several attempts at starting may be necessary to warm-up the lithium-ion battery and thereby increase the starting power. During the starting process, the malfunction indicator lamp lights up.

Warning: If you change down at high engine speed, the rear wheel blocks and the engine races. Do not change into a low gear at high engine speed.

Warning: The engine will not be lubricated unless there is 2-stroke oil in the oil tank. If the oil level warning light lights up, the 2-stroke oil is sufficient for the remaining tank of fuel. As soon as the oil level warning light lights up, ride for no longer than until the remaining fuel in the tank is depleted. At the next opportunity add 2-stroke oil before you refuel.

– First-gear is used for starting off and for steep inclines.

– Shift into a higher gear when conditions allow. To do so, release the throttle while simultaneously pulling the clutch lever, shift into the next gear, release the clutch lever and open the throttle.

– If the cold start function was activated, deactivate the cold start button after the engine has warmed up.

– After reaching maximum speed by fully opening the throttle grip, turn the throttle back so it is ¾ open. This will barely reduce the speed, but fuel consumption will be considerably lower.

– Always open the throttle only as much as the engine can handle – abrupt throttle opening increases fuel consumption.

– To shift down, apply the brakes and close the throttle at the same time.

– Pull the clutch lever and shift into a lower gear, release the clutch lever slowly, and either open the throttle or shift again.

– Switch off the engine if running at idle speed or stationary for a long time (≥ 2 min).

– Avoid frequent or lengthy slipping of the clutch. This causes the gear oil, engine and cooling system to heat up.

– Ride at a low engine speed instead of at a high engine speed with a slipping clutch.

Warning: Excessively forceful application of the brakes blocks the wheels. Adjust application of the brakes to the respective riding situation and riding surface conditions.

Warning: A spongy pressure point on the front or rear brake reduces braking efficiency. Check the brake system and do not continue riding until the problem is eliminated.

Warning: Moisture and dirt impair the brake system. Brake carefully several times to dry out and remove dirt from the brake linings and the brake discs.

– On sandy, wet, or slippery surfaces, use the rear brake.

– Braking should always be completed before you go into a bend. Change down to a lower gear appropriate to your road speed.

– Apply the brakes on the motorcycle.

– Shift the transmission into neutral.

– (All EU/AR/CN models) Press and hold the stop button while the engine is idling until the engine stops.

– (All US models) Press and hold the stop button while the engine is idling until the engine stops.

– Park the motorcycle on firm ground using the side stand.

Warnings and Notes:

– Do not leave the vehicle unattended if the engine is running.

– Protect the vehicle against access by unauthorized persons.

– Let the vehicle parts cool down before you perform any work on the vehicle.

– Park the vehicle on a firm and level surface.

– Ensure that nobody sits on the vehicle when it is parked on a stand.

– Do not park the vehicle near to materials which are highly flammable or explosive.

– Allow the vehicle to cool down before covering it.

– Park the vehicle on a firm and level surface.

– Allow the vehicle to cool down before covering it.

– Switch off the engine.

– Use tension belts or other suitable devices to secure the motorcycle against falling over or rolling away.

Danger: Fire hazard – Fuel is highly flammable. Do not refuel near open flames or lit cigarettes. Switch off the engine. Wipe up spills immediately.

Warning: Danger of poisoning – Fuel is poisonous. Avoid skin, eye, and clothing contact. Do not inhale vapors.

1. Open the fuel tank filler cap.

2. Fill the fuel tank with Super unleaded (ROZ 95) fuel up to level A (35 mm / 1.38 in from the top).

Do not refuel using pre-mixed fuel.

3. Close the fuel tank filler cap.

Warning: Engine failure – The engine will not be lubricated unless there is 2-stroke oil in the oil tank. If the oil level warning light comes on, add 2-stroke oil before you refuel. If the oil hose has been removed or the tank fully depleted, the oil pump must be primed.

1. Open the 2-stroke oil tank cap.

2. Fill the 2-stroke oil tank up to the lower edge of the filler neck. Only use high-grade 2-stroke engine oil from a reputable brand (fully synthetic) appropriate for separate lubrication.

3. Close the 2-stroke oil tank cap.

○ One-time interval

● Periodic interval

○ One-time interval

● Periodic interval

The effect of the low-speed compression adjuster can be seen in slow to normal compression of the shock absorber.

1. Turn adjusting screw (1) clockwise with a screwdriver as far as the last perceptible click. Do not loosen fitting (2).

2. Turn counterclockwise by the number of clicks corresponding to the shock absorber type.

Turn clockwise to increase damping; turn counter-clockwise to reduce damping.

The effect of the high-speed compression adjuster can be seen in the fast compression of the shock absorber.

1. Using an open-end wrench, turn adjusting screw (1) clockwise all the way. Do not loosen fitting (2).

2. Turn counterclockwise by the number of turns corresponding to the shock absorber type.

Turn clockwise to increase damping; turn counter-clockwise to reduce damping.

1. Turn adjusting screw (1) clockwise up to the last perceptible click.

2. Turn counterclockwise by the number of clicks corresponding to the shock absorber type.

Turn clockwise to increase the damping; turn counterclockwise to reduce damping when the shock absorber rebounds.

1. Measure rear wheel unloaded dimension (A):

– Raise the motorcycle with a lift stand.

– Position a sag gage in the rear axle and measure the distance to the marking SAG on the rear fender. Note this value as dimension A.

– Remove the motorcycle from the lift stand.

2. Check the static sag:

– Hold the motorcycle upright with the aid of an assistant.

– Measure the distance again between the rear axle and marking SAG. Note this value as dimension B.

– The static sag is the difference between measurements A and B. The specified value is 37 mm (1.46 in). If the static sag is incorrect, adjust the spring preload of the shock absorber.

3. Check the riding sag:

– With another person holding the motorcycle, the rider, wearing full protective clothing, sits on the seat in a normal sitting position and bounces up and down a few times. The rear wheel suspension levels out.

– Another person measures the distance between the rear axle and marking SAG. Note this value as dimension C.

– The riding sag is the difference between measurements A and C. The specified value is 110 mm (4.33 in). If the riding sag differs, adjust it.

4. Adjust the riding sag:

– If the riding sag is incorrect, you must change the spring preload of the shock absorber or choose a suitable spring.

– After changing the spring, check the static and riding sag again.

Preparatory work:

– Raise the motorcycle with a lift stand.

– Remove the shock absorber and clean it thoroughly.

Main work:

1. Loosen screw (1).

2. Use a hook wrench to turn adjusting ring (2) until the spring is no longer under tension.

3. Measure the total spring length while it is not under tension.

4. Tension the spring by turning adjusting ring (2) to the specified dimension A.

Guideline: Spring preload 12 mm (0.47 in)

5. Tighten screw (1).

Guideline: Screw, shock absorber adjusting ring – M5 – 5 Nm (3.7 lbf ft)

Finishing work:

– Install the shock absorber.

– Remove the motorcycle from the lift stand.

The compression damping is located in the left fork leg COMP (white adjuster). The rebound damping is in the right fork leg REB (red adjuster).

1. Turn the white adjuster (1) clockwise as far as it will go.

2. Turn counterclockwise by the number of clicks corresponding to the fork type.

Turn clockwise to increase damping; turn counter-clockwise to reduce damping during compression.

The rebound damping is located in the right fork leg REB (red adjuster).

1. Turn the red adjuster (1) clockwise as far as it will go.

2. Turn counterclockwise by the number of clicks corresponding to the fork type.

Turn clockwise to increase damping; turn counter-clockwise to reduce damping when the shock absorber rebounds.

Preparatory work:

– Raise the motorcycle with a lift stand.

Main work:

1. Turn T-grips (1) counterclockwise all the way. Marking +0 aligns with the right T-grip on both fork legs.

2. Turn the T-grips clockwise. Make the adjustment by hand only. Make the same adjustment on both fork legs.

The T-grips engage noticeably at the numerical values. Adjust the spring preload to the numerical values only.

Finishing work:

– Remove the motorcycle from the lift stand.

Warning: A repaired handlebar poses a safety risk. If the handlebar is bent or straightened, the material becomes fatigued. Change the handlebar if it is damaged or bent.

The handlebar can be mounted in four different positions.

1. Remove screws (1). Take off the handlebar clamps. Remove the handlebar and lay it to one side. Cover components to protect them against damage and do not kink cables/lines.

2. Remove screws (2). Take off the handlebar supports.

3. Place the handlebar supports in the required position. Mount and tighten screws (2).

– Guideline: Screw, handlebar support – M10 – 40 Nm (29.5 lbf ft) – Loctite® 243™. Position supports evenly.

4. Position the handlebar. Make sure cables and wiring are positioned correctly.

5. Position the handlebar clamps. Mount screws (1) and tighten evenly.

– Guideline: Screw, handlebar clamp – M8 – 20 Nm (14.8 lbf ft). Make sure the gap widths are even.

Preparatory work:

– Raise the motorcycle with a lift stand.

Main work:

1. Release bleeder screws (1). Any excess pressure escapes from the interior of the fork.

2. Tighten the bleeder screws.

Finishing work:

– Remove the motorcycle from the lift stand.

The dust boots remove dust and coarse dirt particles from the inside fork tubes. Over time, dirt can accumulate behind the dust boots. If this dirt is not removed, the oil seals behind can start to leak.

Preparatory work:

– Raise the motorcycle with a lift stand.

– Remove the fork protector.

Main work:

1. Push dust boots (1) of both fork legs downward.

2. Clean and oil the dust boots and inner fork tubes of both fork legs with universal oil spray.

3. Press the dust boots back into their installation position and remove excess oil.

Finishing work:

– Install the fork protector.

– Remove the motorcycle from the lift stand.

Removing the fork legs:

1. Remove the headlight mask with the headlight.

2. Raise the motorcycle with a lift stand.

3. Remove the front wheel.

4. (All TE standard models) Remove screws (1) and take off the clamp.

5. (All TE special models) Remove screws (1), then screws (2) to take off the clamp and brake caliper. Let the caliper hang loosely.

6. Loosen screws (3). Remove the left fork leg.

7. Loosen screws (4). Remove the right fork leg.

Installing the fork legs:

1. Position the fork legs. Bleeder screws (1) should be positioned toward the front. The second milled groove from the top must be flush with the upper edge of the upper triple clamp.

2. Tighten screws (2) of the top triple clamp to M8 / 17 Nm (12.5 lbf ft).

3. Tighten screws (3) of the bottom triple clamp to M8 / 15 Nm (11.1 lbf ft).

4. Position the brake caliper, and mount and tighten screws (4) to M8 / 25 Nm (18.4 lbf ft) with Loctite® 243™.

5. Mount the cable ties. Position the brake line, wiring harness, and clamp. Mount and tighten screws (5).

6. Install the front wheel and headlight mask.

7. Check the headlight setting.

Removing the shock absorber:

1. Raise the motorcycle with a lift stand.

2. Remove cable ties, then screws (1) with washers. Detach frame protector in area A.

3. Remove screw (2) and fitting (3). Raise the link fork slightly to help.

4. Press angle lever (4) to the rear, and linkage lever (5) downward.

5. (All EU/AR models) Disconnect plug-in connector (6) on the brake light switch.

6. (All TE standard models) Remove screws (7) and pull off the foot brake cylinder.

7. (All TE special models) Remove screws (7) and pull off the foot brake cylinder.

8. Remove the connecting link of the chain and take off the chain.

9. Remove nut (8) and pull out the swingarm pivot. Push the link fork back and secure it.

10. Hold the shock absorber and remove screw (9). Remove the shock absorber from the bottom.

Installing the shock absorber:

1. Carefully position the shock absorber from the bottom. Mount and tighten top screw (1) to M10 / 60 Nm (44.3 lbf ft) with Loctite® 2701™.

2. Position the link fork and mount the swingarm pivot. Pay attention to flat area A. Mount and tighten nut (2) to M16x1.5 / 100 Nm (73.8 lbf ft).

3. Mount and connect the chain. The closed side of the chain joint lock must face the direction of travel.

4. (All EU/AR models) Join plug-in connector (3) of the brake light switch.

5. Position the foot brake cylinder so push rod (4) engages. Mount and tighten screws (5) to M6 / 10 Nm (7.4 lbf ft).

6. Position the angle lever and linkage lever. Mount and tighten fitting (6). Nut M14x1.5 to 60 Nm (44.3 lbf ft). Pay attention to flat area B.

7. Mount and tighten bottom shock absorber screw (7) to M10 / 60 Nm (44.3 lbf ft) with Loctite® 2701™. Raise the link fork slightly if needed.

8. Attach the frame protector in area C. Mount and tighten screws (8) with washers to M5 / 3 Nm (2.2 lbf ft). Mount new cable ties.

9. Remove the motorcycle from the lift stand.

Removing the seat:

1. Remove the air filter box cover.

2. Remove screw (1).

3. Raise the rear of the seat, pull the seat back, and lift it off.

Mounting the seat:

1. Mount the front of the seat on the collar bushing of the fuel tank and the rear in the bracket.

2. Push the seat forward. Make sure the seat is latched in place correctly.

3. Mount and tighten screw (1). Guideline: M6, 10 Nm (7.4 lbf ft).

4. Install the air filter box cover.

Note: Unfiltered intake air will damage the engine. Only operate the vehicle with an air filter equipped.

Removing the air filter:

1. Remove the air filter box cover.

2. Detach retaining tab (1). Remove the air filter with its support.

3. Remove the air filter from the air filter support.

Cleaning the air filter:

1. Wash the air filter thoroughly in special air filter cleaner and allow it to dry properly. Only press the air filter to dry it, never wring it out.

2. Oil the dry air filter with a high-grade oil for foam air filters.

3. Clean the air filter box and the intake flange.

Installing the air filter:

1. Mount the clean air filter on the air filter support.

2. Grease the air filter in area A with long-life grease.

3. Insert the air filter and position retaining pin (1) in bushing B. The air filter must be correctly positioned.

4. Insert retaining tab (3). Retaining pin (2) is secured with retaining tab (3).

5. Install the air filter box cover.

Warning: The exhaust system gets very hot. Allow it to cool down before performing any work.

Preparatory work:

– Remove the main silencer.

Main work:

1. Remove screws (1). Pull out inner tube (2) with O-ring (3).

2. Pull glass fiber yarn filling (4) from the inner tube.

3. Clean the parts and check for damage.

4. Mount new glass fiber yarn filling (4) on the inner tube.

5. Push outer tube (5) over the inner tube with the new filling and the O-ring.

6. Mount and tighten all screws (1). Guideline: M5, 7 Nm (5.2 lbf ft).

Finishing work:

– Install the main silencer.

Danger: Fire Hazard. Fuel is highly flammable. Avoid sparks, open flames, and ensure no fuel is spilled.

Removing the fuel tank:

1. Remove the air filter box cover, seat, and right side cover.

2. Unplug connector (1) of the fuel pump.

3. Clean quick release coupling (2) with compressed air.

4. Disconnect the quick release coupling. Mount wash cap set (3).

5. Remove screws (4). (All EU/AR models) Hang the horn and bracket to one side.

6. Remove screw (5) with the rubber bushing. Pull the fuel tank breather hose off the lid.

7. Pull both spoilers laterally off the radiator and lift off the fuel tank.

Installing the fuel tank:

1. Check the throttle cable routing. Position the fuel tank and fit the spoilers to the radiator bracket. Ensure no cables are trapped.

2. Attach the fuel tank breather hose.

3. Mount and tighten screw (1) with the rubber bushing to M6 / 10 Nm (7.4 lbf ft).

4. (All EU/AR models) Position the horn with the horn bracket.

5. Mount and tighten screws (2) to M6 / 10 Nm (7.4 lbf ft).

6. Plug in connector (3) for the fuel pump.

7. Remove the wash cap set. Clean the quick release coupling.

8. Lubricate the O-ring of the coupling with silicone spray and join quick release coupling (4).

9. Install the right side cover, seat, and air filter box cover.

Warning: Incorrect chain tension damages components and can cause accidents. Check tension regularly.

Checking chain tension:

1. Raise the motorcycle with a lift stand.

2. Pull the chain upward at the end of the chain sliding piece to measure tension A. The lower chain section (1) must be taut.

– Guideline: Chain tension should be 55 … 58 mm (2.17 … 2.28 in).

3. If tension is incorrect, adjust it.

Adjusting chain tension:

1. Loosen nut (1) and nuts (2).

2. Turn adjusting screws (3) on the left and right to adjust tension. Ensure the markings on both chain adjusters are in the same position relative to reference marks A for correct wheel alignment.

3. Tighten nuts (2).

4. Make sure chain adjusters (4) are fitted correctly on adjusting screws (3).

5. Tighten nut (1). Guideline: Nut, rear wheel spindle – M20x1.5 – 80 Nm (59 lbf ft).

6. Remove the motorcycle from the lift stand.

1. Shift the transmission into neutral.

2. Check the chain, rear sprocket, and engine sprocket for wear. If any are worn, change the entire drivetrain kit together.

3. To check chain wear, pull on the top section of the chain with a weight of 10 … 15 kg (22 … 33 lb.).

4. Measure the distance B of 18 chain rollers in the lower chain section. Repeat at different positions.

– Maximum distance B should be 272 mm (10.71 in). If it is greater, change the drivetrain kit.

5. Check the chain sliding guard for wear. If the lower edge of the chain pins is in line with or below the guard, change it. Ensure it is firmly seated.

6. Check the chain sliding piece for wear. If the lower edge of the chain pins is in line with or below the piece, change it. Ensure it is firmly seated.

7. Check the chain guide for wear. If the light part of the guide is worn, change it. Ensure it is firmly seated.

Adjust the basic position of the clutch lever to your hand size by turning adjusting screw (1). Do not make any adjustments while riding.

All TE standard models:

– Turning the adjusting screw counterclockwise moves the clutch lever away from the handlebar.

– Turning the adjusting screw clockwise moves the clutch lever closer to the handlebar.

All TE special models:

– Turning the adjusting screw counterclockwise moves the clutch lever away from the handlebar.

– Turning the adjusting screw clockwise moves the clutch lever closer to the handlebar.

Warning: Brake fluid causes skin irritation. Avoid contact and wear protective gear. Use only clean brake fluid from a sealed container. Never use DOT 5 brake fluid.

Checking/Correcting the Fluid Level:

1. Move the hydraulic clutch fluid reservoir on the handlebar to a horizontal position.

2. Remove screws (1), then take off cover (2) with membrane (3).

3. Check the fluid level. It should be 4 mm (0.16 in) below the container rim.

4. If the level is low, correct it with Brake fluid DOT 4 / DOT 5.1.

5. Position the cover with the membrane. Mount and tighten the screws. Use water to clean up any spilled fluid.

Changing the Hydraulic Clutch Fluid:

1. Move the reservoir to a horizontal position and remove the cover and membrane.

2. Fill a bleeding syringe with appropriate hydraulic fluid.

3. On the slave cylinder, remove the protection cap and bleeder screw (5), then mount the bleeding syringe (4).

4. Press the fluid into the system until it emerges from hole (6) of the master cylinder without bubbles. Occasionally extract fluid from the reservoir to prevent overflowing.

5. Remove the bleeding syringe. Mount and tighten the bleeder screw and mount the protection cap.

6. Correct the fluid level in the reservoir and reinstall the cover and membrane.

Adjusting Basic Position (All TE standard models):

– Adjust the basic position of the hand brake lever to your hand size by turning adjusting screw (1).

– Turning it clockwise decreases the distance to the handlebar; counterclockwise increases it.

Checking Free Travel (All TE special models):

Warning: No free travel can cause the brake system to overheat and fail.

– Push the hand brake lever to the handlebar and check free travel A. It should be ≥ 3 mm (≥ 0.12 in). If not, adjust it.

Adjusting Free Travel (All TE special models):

– Adjust the free travel of the hand brake lever with adjusting screw (1).

Warning: Worn-out brake linings reduce braking effect. Replace immediately if worn.

Checking the linings:

Check the brake linings for minimum thickness A. It should be ≥ 1 mm (≥ 0.04 in). If it’s less, or if there is damage or cracking, change the linings.

Changing the linings:

1. Move the brake fluid reservoir to a horizontal position and remove the cover.

2. Manually press the brake caliper toward the brake disc to push back the pistons. Extract some fluid if necessary.

3. Remove cotter pin (4) and pull out pin (5).

4. Remove the brake linings. Clean the caliper and bracket.

5. Check that spring plate (6) and sliding plate (7) are seated correctly.

6. Insert new brake linings. Always change in pairs.

7. Mount pin (5) ensuring spring plate (6) engages in its groove. Mount cotter pins (4).

8. Operate the hand brake lever repeatedly until linings are in contact with the disc and there is a pressure point.

9. Add brake fluid up to the correct level and reinstall the reservoir cover.

Warning: Lack of free travel can cause the rear brake to overheat and fail.

Checking free travel:

1. Disconnect spring (1).

2. Move the foot brake lever back and forth to check free travel A. It should be 3 … 5 mm (0.12 … 0.2 in).

3. If it does not meet specifications, adjust the basic position.

4. Reconnect spring (1).

Adjusting basic position:

1. Detach spring (1).

2. Loosen nut (4) and turn push rod (5) back for maximum free travel.

3. To adjust the lever’s basic position, loosen nut (2) and turn screw (3).

4. Turn push rod (5) until free travel A is correct.

5. Hold screw (3) and tighten nut (2) to M8 / 20 Nm (14.8 lbf ft).

6. Hold push rod (5) and tighten nut (4) to M6 / 10 Nm (7.4 lbf ft).

7. Attach spring (1).

Warning: An insufficient or old brake fluid level can cause the brake system to fail.

Checking the level:

Position the vehicle vertically. Check the brake fluid level in level viewer (1). When the level has dropped to the lower edge A of the viewer, you must add fluid.

Adding fluid:

1. Check the rear brake linings first.

2. Stand the vehicle upright. Remove cable ties on the frame protector.

3. Remove screw cap (1) with membrane (2) and the shim.

4. Add brake fluid DOT 4 / DOT 5.1 up to the marking A.

5. Mount and tighten the screw cap with the membrane and shim.

6. Mount new cable ties on the frame protector.

Removing the front wheel:

1. Raise the motorcycle with a lift stand.

2. Manually press the brake caliper toward the brake disc to push back the brake pistons.

3. Loosen screw (1) by several rotations. Loosen screws (2).

4. Press on screw (1) to push the wheel spindle out of the axle clamp. Remove screw (1).

5. Hold the front wheel and remove the wheel spindle. Take the front wheel out of the fork. Do not actuate the hand brake lever when the wheel is removed.

6. Remove spacers (3). (All TE special models) Remove brake disc guard (4) as well.

Installing the front wheel:

1. Check the wheel bearing for damage and wear. Clean and grease shaft seal rings (1) and contact surfaces A of the spacers with long-life grease.

2. Insert the spacers. Clean and grease the wheel spindle.

3. (All TE special models) Align the brake disc guard so that distances B and C are equal in size.

4. Jack up the front wheel into the fork, position it, and insert the wheel spindle. The brake linings must be correctly positioned.

5. Mount and tighten screw (2). Guideline: M20x1.5, 35 Nm (25.8 lbf ft).

6. Operate the hand brake lever several times until the brake linings are seated correctly.

7. Remove the motorcycle from the lift stand. Operate the front brake and compress the fork a few times firmly until the fork legs straighten.

8. Tighten screws (3). Guideline: M8, 15 Nm (11.1 lbf ft).

Removing the rear wheel:

1. Raise the motorcycle with a lift stand.

2. Manually press the brake caliper toward the brake disc to push back the brake piston.

3. Remove nut (1). Take off chain adjuster (2). Pull out wheel spindle (3) far enough to push the wheel forward.

4. Push the rear wheel forward and remove the chain from the rear sprocket.

5. Hold the rear wheel and remove the wheel spindle. Take the rear wheel out of the link fork. Do not operate the foot brake lever when the wheel is removed.

6. Remove spacers (4).

Installing the rear wheel:

1. Check the wheel bearing. Clean and grease shaft seal rings (1) and contact surfaces A of the spacers with long-life grease.

2. Insert the spacers. Clean and lightly grease the wheel spindle.

3. Position the rear wheel and insert wheel spindle (2). The brake linings must be correctly positioned.

4. Mount the chain.

5. Position chain adjuster (3). Mount nut (4), but do not tighten it yet.

6. Check the chain tension and adjust if necessary.

7. Tighten nut (4). Guideline: M20x1.5, 80 Nm (59 lbf ft).

8. Operate the foot brake lever repeatedly until the brake linings are in contact with the disc.

9. Remove the motorcycle from the lift stand.

Tire Condition and Tread Depth:

– Check the front and rear tires for cuts, run-in objects, and other damage. Change tires if damaged.

– Check the tread depth. Adhere to the legally required minimum tread depth. The specified minimum is ≥ 2 mm (≥ 0.08 in). Change tires if the depth is less than the minimum.

Tire Age:

– Check the tire age. The tire date of manufacture is usually the last four digits of the DOT number (week and year). It is recommended that tires be changed after 5 years at the latest, regardless of wear.

Tire Pressure:

– Remove the protection cap and check tire pressure when tires are cold.

– If pressure is not correct, adjust it and mount the protection cap.

Warning: Incorrectly tensioned spokes impair handling and can lead to damage. Check spoke tension regularly, especially on a new vehicle.

1. Strike each spoke briefly using a screwdriver blade. You should hear a high note. If you hear different tone frequencies from spokes of equal length and diameter, this indicates different spoke tensions.

2. If the spoke tension differs, correct the spoke tension.

3. Check the spoke torque.

Warning: Risk of injury. 12 V batteries contain harmful substances. Keep away from children, sparks, and open flames. Only charge in well-ventilated rooms.

Removing the 12-V battery:

1. Remove the air filter box cover and the seat.

2. Disconnect negative cable (1) from the 12-V battery.

3. Pull back positive terminal cover (2) and disconnect the positive cable.

4. Pull EFI control unit (3) upward off rubber lugs (4) and hang to the side.

5. Pull off starter relay (5) and fuse box (6) from the battery compartment and hang to the side.

6. Detach wiring harness (7), disconnect relays (8) and plug (9), and hang to the side.

7. Remove screw (10) and detach the battery compartment.

8. Lift out the 12-V battery.

Installing the 12-V battery:

1. Insert the 12-V battery into the compartment with terminals facing forward and secure with holding bracket (1).

2. Mount and tighten screw (2) to M6 / 10 Nm (7.4 lbf ft).

3. Place relays (3) and connector (4) on the compartment and attach wiring harness (5).

4. Attach starter relay (6) and fuse box (7) to the compartment.

5. Secure EFI control unit (8) with the rubber lugs (9).

6. Connect positive cable (10) to the battery. Tighten screw to M5 / 2.5 Nm (1.84 lbf ft). Ensure contact disk A is mounted correctly.

7. Slide positive terminal cover (14) over the terminal.

8. Connect negative cable (11) to the battery. Tighten screw to M5 / 2.5 Nm (1.84 lbf ft).

9. Mount the seat and install the air filter box cover.

Warning: Charge in a well-ventilated area away from flammable materials. Do not charge a deeply discharged battery (below 9 V).

1. Remove the 12-V battery.

2. Check the battery voltage. If it is less than 9 V, do not charge it; replace it.

3. If voltage is ≥ 9 V, charge the 12-V battery.

Use a suitable battery charger for lithium iron phosphate batteries. Never remove cover (1) of the battery.

4. Switch off the battery charger after charging and disconnect from the 12-V battery.

5. Install the 12-V battery.

Warning: Fire hazard. Only use fuses with the required ampere value. Do not bypass or repair fuses.

Changing main fuse:

1. Remove the air filter box cover and the seat.

2. Pull the EFI control unit (1) upward off the rubber lugs (2) and hang to the side.

3. Pull starter relay (3) from the holder.

4. Take off protection caps (4). Remove faulty main fuse (5). A faulty fuse has a burned-out fuse wire A. A spare fuse (6) is located in the starter relay.

5. Insert a new 20 A main fuse (58011109120).

6. Check that the electrical system is functioning properly.

7. Attach the protection caps (4), mount the starter relay (3), and mount the EFI control unit (1).

Changing individual fuses:

1. The fuse box is located under the seat. Remove the air filter box cover and seat.

2. Open fuse box cover (1) and remove the faulty fuse.

3. Insert a spare fuse with the correct rating.

4. Check the function of the electrical power consumer and close the fuse box cover (1).

5. Mount the seat and install the air filter box cover.

Fuse Ratings (All EU/AR models):

• Fuse 1 – 10 A – EFI, oil pump, instruments, etc.

• Fuse 2 – 10 A – horn, brake light, radiator fan, turn signal

• Fuse 3 – 10 A – high/low beam, position light, etc.

• Fuse 4 – 5 A – fuel pump

Fuse Ratings (All US/CN models):

• Fuse 1 – 10 A – EFI, oil pump, instruments, etc.

• Fuse 2 – 10 A – radiator fan (optional)

• Fuse 3 – 10 A – low beam, position light, tail light

• Fuse 4 – 5 A – fuel pump

• Fuses res – 10 A – spare fuse

Note: Grease on the reflector or bulb reduces light intensity. Clean and degrease bulbs before mounting and do not touch with bare hands.

1. Remove the headlight mask with the headlight.

2. Turn protection cap (1) with the underlying bulb socket counterclockwise and remove it.

3. Pull bulb socket (2) of the position light out of the reflector.

4. Pull out headlight bulb (3).

5. Insert the new headlight bulb (HS1/socket BX43t).

6. Insert the protection cap with the bulb socket into the reflector and turn it clockwise all the way, ensuring O-ring (4) is correctly positioned.

7. Insert the bulb socket of the position light into the reflector.

8. Install the headlight mask and check the headlight setting.

1. Remove the screw on the rear of the turn signal housing.

2. Carefully remove turn signal glass (1).

3. Lightly squeeze orange cap (2) and take it off.

4. Press the turn signal bulb lightly into the socket, turn it counterclockwise by about 30°, and take it out.

5. Press the new turn signal bulb (R10W/socket BA15s) carefully into the socket and turn it clockwise until it stops.

6. Mount the orange cap and position the turn signal glass.

7. Insert the screw and tighten lightly.

8. Check that the turn signal system is functioning properly.

Checking the headlight setting:

1. Park the vehicle on a horizontal surface in front of a light-colored wall and make a mark at the height of the center of the low beam headlight.

2. Make another mark at a distance B (5 cm / 2 in) under the first marking.

3. Position the vehicle vertically at a distance A (5 m / 16 ft) away from the wall.

4. The rider sits on the motorcycle. Switch on the low beam.

5. Check the headlight setting. The boundary between light and dark must be exactly on the lower mark. If not, adjust the headlight range.

Adjusting the headlight range:

1. Loosen screw (1).

2. Adjust the headlight range by pivoting the headlight.

3. Tighten screw (1).

1. Remove the headlight mask with the headlight.

2. Remove screws (1) with the washers.

3. Pull the combination instrument upward out of the holder.

4. Using a coin, turn protection cap (2) all the way counter-clockwise and take it off.

5. Remove combination instrument battery (3).

6. Insert the new combination instrument battery (CR 2032) with the label facing outward.

7. Check the O-ring of the protection cap for correct seating.

8. Position protection cap (2) and turn all the way clockwise using a coin.

9. Press any button on the combination instrument to activate it.

10. Position the combination instrument in the holder and tighten the screws with washers.

11. Install the headlight mask and adjust the combination instrument settings.

Warning: Coolant gets very hot and is under pressure. Allow the system to cool before working. Coolant is toxic; avoid contact.

Draining the coolant:

1. Ensure the engine is cold. Remove the engine guard.

2. Position the motorcycle upright and place a container under the water pump cover.

3. Remove screw (1). Take off radiator cap (2).

4. Completely drain the coolant.

5. Mount and tighten screw (1) with a new seal ring. Guideline: M6, 10 Nm (7.4 lbf ft).

Refilling with coolant:

1. Make sure screw (1) is tightened and the motorcycle is upright.

2. Pour coolant in up to 10 mm (0.39 in) above the radiator fins.

3. Push protection cap (2) upward over the coolant temperature sensor.

4. Unplug connector (3) and remove sensor (4) with O-ring. Wait until coolant escapes without bubbles.

5. Mount and tighten sensor (4) with O-ring. Guideline: M10x1.25, 12 Nm (8.9 lbf ft). Plug in connector (3).

6. Position protection cap (2) and pour coolant in again up to 10 mm (0.39 in) above the radiator fins.

7. Mount radiator cap (5). Start the engine and let it warm up.

8. Allow the engine to cool down and check the coolant level again. Install the engine guard.

Checking the play:

1. Turn the handlebar to the right. Turn the throttle grip slightly back and forth to determine the play in the throttle cable A. It should be 3 … 5 mm (0.12 … 0.2 in).

2. Start the engine and let it run at idle. Move the handlebar to and fro over the entire steering range. The idle speed must not change. If it does, adjust the play.

Adjusting the play:

1. Push back sleeve (1).

2. Loosen nut (2) and turn adjusting screw (3) in as far as possible.

3. Loosen nut (4) and turn adjusting screw (5) in as far as possible.

4. Turn adjusting screw (3) so that there is play in the throttle cable at the throttle grip.

5. Unscrew adjusting screw (5) until the smooth operation or play in the throttle cable is worsened, then turn it in approx. two turns further.

6. Tighten nut (4), then tighten nut (2).

7. Slide on sleeve (1) and check the throttle grip for smooth operation.

Warning: The engine may go out if the idle speed is too low.

1. Run the engine until warm. The cold start button must be deactivated.

2. Adjust the idle speed by turning the idle speed adjusting screw (1).

– Guideline: Idle speed 1,400 … 1,500 rpm.

– Turn clockwise to decrease the idle speed.

– Turn counterclockwise to increase the idle speed.

– Make the setting in small steps.

If the vehicle is transported over great height differences, the ambient pressure must be reprogrammed.

1. Start up the vehicle at a new height above sea level and switch off the engine again.

2. Wait for at least five seconds.

3. Start the vehicle again and check the response of the vehicle.

» If the response has not improved, repeat the procedure.

Checking the position:

Sit on the vehicle in the riding position and determine distance A between the upper edge of your boot and the shift lever. It should be 10 … 20 mm (0.39 … 0.79 in). If not, adjust it.

Adjusting the position:

1. Remove screw (1) with the washers and take off shift lever (2).

2. Clean gear teeth A of the shift lever and shift shaft.

3. Mount the shift lever on the shift shaft in the required position and engage gearing. The shift lever must not come into contact with any other vehicle components.

4. Mount and tighten screw (1) with washers. Guideline: M6, 14 Nm (10.3 lbf ft), Loctite® 243™.

Danger: Fire hazard. Fuel is highly flammable. Avoid sparks and open flames.

1. Clean the quick release coupling (1) thoroughly with compressed air. Dirt must not enter the fuel line.

2. Disconnect the quick release coupling. Remaining fuel may flow out.

3. Pull fuel screen (2) out of the connecting piece.

4. Insert the new fuel screen all the way into the connecting piece.

5. Spray silicone spray onto a lint-free cleaning cloth and lightly lubricate the O-ring of the quick-release coupling.

6. Join the quick release coupling.

This procedure is necessary if the 2-stroke oil hose has been removed or the tank has been fully depleted.

Condition: The engine is off.

1. Remove the air filter box cover and seat. Stand the motorcycle upright.

2. Check the 2-stroke oil level and fill if necessary.

3. Pull the EFI control unit (1) off the rubber lugs (2) and hang it to the side.

4. Pull diagnostics connector (3) off the holder.

5. Put the throttle grip (4) into the full throttle position and secure it.

6. Plug the wake-up connector (5) into the diagnostics connector (6). The combination instrument lighting will activate.

7. Wait for at least five seconds. Release the fixing means from the throttle grip. The oil pump is now timed and will be clearly audible.

8. Wait until you can no longer hear the oil pump operating.

9. Disconnect the wake-up connector.

10. Check if air bubbles are visible in the hose (7). If so, repeat the entire procedure.

11. Mount the protection cap on the diagnostics connector and mount the EFI control unit on the rubber lugs.

12. Mount the seat and install the air filter box cover.

Checking the gear oil level:

This must be checked when the engine is cold.

1. Stand the motorcycle upright on a horizontal surface.

2. Remove gear oil level monitoring screw (1). A small quantity of gear oil must run out of the drilled hole.

3. If no oil runs out, add gear oil.

4. Mount and tighten the monitoring screw. Guideline: M6, 8 Nm (5.9 lbf ft).

Changing the gear oil:

Warning: Engine and gear oil get very hot. Wear protective clothing.

1. Drain the gear oil while the engine is at operating temperature. Remove the engine guard.

2. Park the motorcycle on a level surface with a container underneath.

3. Remove gear oil drain plug (1) with magnet and let the oil drain fully.

4. Thoroughly clean the drain plug and the sealing surface on the engine.

5. Mount and tighten the drain plug (1) with the magnet and a new seal ring. Guideline: M12x1.5, 20 Nm (14.8 lbf ft).

6. Remove filler plug (2) with the O-ring and fill up with 0.80 l (0.85 qt.) of Engine oil (15W/50).

7. Mount and tighten the filler plug with the O-ring.

8. Start the engine, check for leaks, and then check the gear oil level.

Note: High-pressure water can damage components. Maintain a minimum distance of 60 cm (23.6 in) and do not spray directly on electrical parts, connectors, cables, or bearings.

1. Close off the exhaust system to keep water from entering.

2. Remove coarse dirt with a gentle water jet.

3. Spray heavily soiled parts with a commercial motorcycle cleaner and clean with a brush.

4. After rinsing with a gentle spray of water, allow it to dry thoroughly. Remove the exhaust closure.

5. After cleaning, ride the vehicle a short distance until the engine warms up to evaporate water from inaccessible locations.

6. After the motorcycle has cooled, lubricate all moving parts and pivot points.

7. Clean the chain.

8. Treat bare metal (except brake discs and exhaust) with a corrosion inhibitor.

9. Treat plastic and powder-coated parts with a mild cleaning and care product.

10. (All EU/AR models) Oil the steering lock.

If you use the motorcycle in winter, be aware of aggressive road salt. Use cold water for cleaning after riding on salted roads, as warm water enhances corrosion.

– Clean the motorcycle.

– Clean the brakes. After EVERY trip on salted roads, thoroughly clean the brake calipers and linings with cold water and dry them carefully.

– Treat the engine, link fork, and all other bare or zinc-plated parts (except brake discs) with a wax-based corrosion inhibitor. Do not get inhibitor on the brake discs.

– Clean the chain.

1. Clean the motorcycle.

2. Change the gear oil.

3. Check the antifreeze and coolant level.

4. When refueling for the last time before storage, add fuel additive and refuel.

5. Check tire pressure.

6. Remove the 12-V battery and charge it. The ideal storage temperature for the lithium-ion battery is 10 … 20 °C (50 … 68 °F).

7. Store the vehicle in a dry location not subject to large temperature fluctuations.

8. Raise the motorcycle with a lift stand.

9. Cover the vehicle with a tarp or a similar cover that is permeable to air. Do not use non-porous materials.

1. Remove the motorcycle from the lift stand.

2. Install the 12-V battery.

3. Perform checks and maintenance measures as you would before any ride.

4. Make a test ride.

The blink codes are only displayed by the derestricted version of the vehicle.

All TE 250i models

All TE 300i models

Chassis

Tires

Fork (WPXPLOR 5548)

Shock Absorber (WPXACT 5750)